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Fixin’ up that Broken-Stripped Exhaust Manifold. #765039
Sun Jul 24 2011 05:19 AM
Sun Jul 24 2011 05:19 AM
D
Denny Graham  Offline OP
Extreme Gabster
Joined: Oct 2006
Posts: 11,765
Sandwich, IL
Been working on my original exhaust manifold, it was is in nice shape, meaning it wasn’t all rusted up and pitted like a lot of them are after 60 years. All the casting numbers are still nice and crisp and clear so I wanted to keep it.
But it had some serious problems, like the flange at the head pipe had one ear broken off and one of the studs for the intake to exhaust was loose as a goose caused by the drill wondering when a broken stud removal was attempted.
So after I decided that I’d take a stab at saving it and here are the results so far. http://www.pbase.com/dennygraham/manifolds&page=all
Now, all that’s left is to get the POR15 High Temp Paint on it this week end.
Denny Graham
Sandwich, IL

Re: Fixin’ up that Broken-Stripped Exhaust Manifold. [Re: Denny Graham] #765058
Sun Jul 24 2011 12:05 PM
Sun Jul 24 2011 12:05 PM
P
Pete52  Offline
Shop Shark
Joined: Jan 2009
Posts: 1,693
melrose pk. il.
Nice work Denny

Pete

Re: Fixin’ up that Broken-Stripped Exhaust Manifold. [Re: Pete52] #765070
Sun Jul 24 2011 12:54 PM
Sun Jul 24 2011 12:54 PM
D
Denny Graham  Offline OP
Extreme Gabster
Joined: Oct 2006
Posts: 11,765
Sandwich, IL
Morning Pete, the neighbor's rooster got you up early this morning huh???
Thanks, for the manifolds, I tested a bunch of different rods using the Tig and ended up with the Ni-Rod 99, AWS A5.15, ERNi-CI. I welded a 2" square piece of 3/16 crs to the side of he test manifold with it and bent it over with a hammer, the test welds appear to hold just fine. Of course as I suspected, with out proper heat treat annealing that weld joints are as hard as a rock and that's why I opted to cut back behind the threaded stud hole and weld a new tab on.

So.... I think I saved the original manifold and when it's painted I don't think any one could tell that it's been repaired, 'cept maybe old Bill who‘s keeping an eye on my idea of original! My new SS studs and brass tall nuts should make it a breeze to take apart next time.

Thanks again for the cadavers.
Denny Graham
Sandwich, IL


Last edited by Denny Graham; Sun Jul 24 2011 01:02 PM.
Re: Fixin’ up that Broken-Stripped Exhaust Manifold. [Re: Denny Graham] #765073
Sun Jul 24 2011 01:24 PM
Sun Jul 24 2011 01:24 PM
tclederman  Offline
Boltergeist
Joined: Sep 2001
Posts: 27,953
Jarvisburg, NC

Denny,

I have been using stainless steel studs and long brass bolts for about 13 years. They have allowed me several on-off sequences with no problems.

After you have run that engine/exhaust-manifold for a year or two, I trust you will give us your assessment on the POR-15 High Temp Paint. Have you used this before?


Tim
1954Advance-Design.com
1954 3106 Carryall Suburban - part of the family for 50 years
1954 3104 5-window pickup w/Hydra-Matic - part of the family for 14 years
Z-series (54/55) GMC 350 (2-ton) COE - now part of Dave's family
- If you have to stomp on your foot-pedal starter, either you, or your starter, or your engine, has a problem.
- The 216 and early 235 engine are not "splash oilers" - this is a splash oiler.
Re: Fixin’ up that Broken-Stripped Exhaust Manifold. [Re: tclederman] #765128
Sun Jul 24 2011 04:46 PM
Sun Jul 24 2011 04:46 PM
D
Denny Graham  Offline OP
Extreme Gabster
Joined: Oct 2006
Posts: 11,765
Sandwich, IL
No Tim, I haven’t used the POR15 before. I definitely will add some pics to my album after a while. Obviously POR15 doesn’t have a gray formula that will satisfy me so I’m gonna do some experimenting with tinting it. I’m sure it’s gonna be to light to match The Filling Station gray that I feel is correct so I’ve got some high temp black to darken it up with. I haven’t looked but I’d like to find some blue which I think it may need also.

I made my own SS studs because I couldn’t find any that were exactly like the original ones. Had a hard time with the 304 SS but it was still a fun project making up all my studs and brass nuts for the exhaust and carb mount.

DG

Re: Fixin’ up that Broken-Stripped Exhaust Manifold. [Re: Denny Graham] #765287
Mon Jul 25 2011 02:30 AM
Mon Jul 25 2011 02:30 AM
S
Super55  Offline
Shop Shark
Joined: Sep 2006
Posts: 2,362
Maple Ridge, BC
Where do you get stainless steel exhaust studs and tall brass nuts.... local parts store?


A day without laughter is a day wasted- Charlie Chaplin

When wrestling a grizzly bear, you have to keep at it until the bear gets tired, not when you get tired.


1948 Chevy 2-Ton
Re: Fixin’ up that Broken-Stripped Exhaust Manifold. [Re: Super55] #765344
Mon Jul 25 2011 05:11 AM
Mon Jul 25 2011 05:11 AM
D
Denny Graham  Offline OP
Extreme Gabster
Joined: Oct 2006
Posts: 11,765
Sandwich, IL
I haven't found a source for them so I made my own Paul. http://www.pbase.com/dennygraham/image/136683323/large

DG

Last edited by Denny Graham; Mon Jul 25 2011 05:12 AM.
Re: Fixin’ up that Broken-Stripped Exhaust Manifold. [Re: Denny Graham] #765381
Mon Jul 25 2011 01:14 PM
Mon Jul 25 2011 01:14 PM
tclederman  Offline
Boltergeist
Joined: Sep 2001
Posts: 27,953
Jarvisburg, NC

Denny,

What is the reason for using brass nuts? I have used them because it was suggested to do so? What length nut is considered to be long?

On one of my trucks I used stainless studs and stainless nuts. Is there a disadvantage to using stainless nuts with stainless studs? ( an anti-galling lubricant most likely should be used?)

Totally Stainless sells various lengths/threads of stainless exhaust studs.

I think I found brass coupling nuts at True Value Hardware (Grainger has them, too). It's been a while, but I think I had to run a tap through the nut (from both ends) to remover the divider in the middle of the nut?

I have never used them, but stainless coupling nuts are also available.


Tim
1954Advance-Design.com
1954 3106 Carryall Suburban - part of the family for 50 years
1954 3104 5-window pickup w/Hydra-Matic - part of the family for 14 years
Z-series (54/55) GMC 350 (2-ton) COE - now part of Dave's family
- If you have to stomp on your foot-pedal starter, either you, or your starter, or your engine, has a problem.
- The 216 and early 235 engine are not "splash oilers" - this is a splash oiler.
Re: Fixin’ up that Broken-Stripped Exhaust Manifold. [Re: tclederman] #765404
Mon Jul 25 2011 03:35 PM
Mon Jul 25 2011 03:35 PM
D
Denny Graham  Offline OP
Extreme Gabster
Joined: Oct 2006
Posts: 11,765
Sandwich, IL
When assembling Similar alloys they tend to gall the threads, as it appears your aware of and that‘s why we use Anti-Seize. There in lies the reasoning behind the brass nuts. They don't gall the thread in either fastener and they don't rust. So they’re a breeze to remove down the line. The reason I use the tall nuts is because the brass is not as strong in shear as the steel is, so it's just a little more insurances against the threads pulling out of the nut.

Yes, Totally Stainless sells SS exhaust studs, I think I mentioned that earlier, but none exactly like the ones I wanted, I know I'm a bit strange, but sometimes I'm just a fussy old dude and I want things my way. Also I think I spent more time at the Totally Stainless site looking for studs than time it took me to make my own, and I had them the same day. It seems that all I could find at TS were sets for the more popular cars.
Often it's less trouble for me to head to the basement and make a part than it is spending the whole day driving around and not finding what your want, or surfing the web then sitting at the window for three or four days on the look out for the UPS truck.

How tall are “tall nuts”? I just make them double the length of a standard nut, roughly 5/8”. And again, only takes a few minutes to chuck up some 9/16 brass hex stock, run a 5/16 drill in, run a 3/8-16 tap in the end and slab off a nut, vs. chasing all over the place in search of. This is machine shop 101, very basic type stuff anyone can do if they have access to a little lathe.

All finished with the heavy engine work and ready to move on to some plumbing and then the transmission, FINALLY!
http://www.pbase.com/dennygraham/image/136695239/large
http://www.pbase.com/dennygraham/image/136695297/large
http://www.pbase.com/dennygraham/image/136695313/large

Denny Graham
Sandwich, IL

Re: Fixin’ up that Broken-Stripped Exhaust Manifold. [Re: Denny Graham] #765517
Mon Jul 25 2011 10:00 PM
Mon Jul 25 2011 10:00 PM
N
Nesto426  Offline
Shop Shark
Joined: Mar 2010
Posts: 207
Lincoln, NE
Denny,

I have a broken ear on my manifold also. I found two replacements and they are all messed up worse than just a broken ear. I wonder if I can find a shop around Lincoln, Ne to fix mine like you did. Looks great!

Did you media blast the manifold to get it so clean?


Tom

1965 Chevy C10, 230 straight six, 2WD, 4-speed manual.

http://s1094.photobucket.com/albums/i442/nesto426/1965%20Chevy%20C1/
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